Still RX60-25 User manual

Original instructions
Electric forklift truck
RX60-25
RX60-25/600
RX60-25L
RX60-25L/600
RX60-30
RX60-30L
RX60-30L/600
RX60-35
6345 6346 6347 6348 6353
6354 6355 6356
56338011803 EN - 10/2016

Preface
g
Address of manufacturer and
contact details
STILL GmbH
Berzeliusstraße 10
22113 Hamburg, Germany
Tel. [phone]
Fax: [phone]
Email: [email protected]
Website: http://www.still.de
56338011803 EN - 10/2016 I

Table of contents
g
1 Foreword
Your truck .......................................................... 2
General ............................................................ 2
CElabelling ......................................................... 2
EC declaration of conformity in accordance with Machinery Directive ............... 3
Accessories ......................................................... 4
Information about the documentation ...................................... 5
Documentationscope ................................................. 5
Issue date and topicality oftheoperatinginstructions ........................... 6
Copyrightandtrademarkrights ........................................... 6
Explanation of information symbols used . . ................................. 6
Listofabbreviations ................................................... 7
Definitionofdirections ................................................. 9
Schematicviews ..................................................... 9
Environmental considerations .......................................... 11
Packaging ......................................................... 11
Disposal of components and batteries ..................................... 11
2 Introduction
Using the truck ...................................................... 14
Proper usage ....................................................... 14
Proper use during towing .............................................. 14
Impermissibleuse ................................................... 14
Placeofuse ........................................................ 15
Parkingintemperaturesbelow-10°C ..................................... 16
Using working platforms ............................................... 16
Residual risk ....................................................... 17
Residual dangers, residual risks ......................................... 17
Special risks associatedwithusingthetruckandattachments ................... 18
Overviewofhazardsandcountermeasures ................................. 20
Danger to employees . . ............................................... 23
3Safety
Definition of responsible persons ........................................ 26
Operatingcompany .................................................. 26
Specialist .......................................................... 26
Drivers ........................................................... 27
Basic principles for safe operation ....................................... 29
Insurance cover on company premises .................................... 29
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Changes and retrofitting ............................................... 29
Changes to the overhead guard and roof loads . . . ........................... 32
Warning regarding non-originalparts ..................................... 32
Damage, defects and misuse of safety systems . . . ........................... 33
Tyres ............................................................. 33
Medicalequipment ................................................... 34
Exercise caution when handling gas springs and accumulators .................. 35
Lengthoftheforkarms ................................................ 35
Safety tests ........................................................ 37
Regularsafetyinspectionofthetruck ..................................... 37
Insulationtesting .................................................... 37
Safety regulations for handling consumables ............................... 39
Permissibleconsumables ............................................. 39
Oils .............................................................. 39
Hydraulicfluid ...................................................... 40
Batteryacid ........................................................ 41
Disposalofconsumables .............................................. 42
Emissions ......................................................... 43
4Overviews
General view ....................................................... 48
General view of driver’s compartment ..................................... 50
Operating devices and display elements ................................... 52
Display operating unit ................................................. 52
Operatingdevicesforhydraulicandtractionfunctions ......................... 54
Multi-lever ......................................................... 55
Doublemini-lever .................................................... 56
Three-waymini-lever ................................................. 57
Four-way mini-lever .................................................. 58
Joystick4Plus ...................................................... 59
Fingertip .......................................................... 60
Miniconsole ....................................................... 61
Identification points .................................................. 62
Overview .......................................................... 62
Nameplate ......................................................... 64
Productionnumber .................................................. 65
StVZO (Road Traffic Licensing Regulations) information ....................... 65
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5 Operation
Checks and tasks to be carried out prior to commissioning ...................... 68
Visualinspections ................................................... 68
Fillingthewashersystem .............................................. 70
Checking the condition of the wheels and tyres .............................. 71
Adjusting the MSG 65/MSG 75 driver’sseat ................................ 72
Adjustingthearmrest ................................................. 76
Adjustingthesteeringcolumn ........................................... 77
Commissioning ..................................................... 78
Climbinginandoutofthetruck .......................................... 78
Connecting the battery male connector .................................... 80
Shelvesandcupholders .............................................. 80
Unlockingtheemergencyoffswitch ...................................... 81
Switchingonthekeyswitch ............................................ 81
Access authorisation withPINcode(variant) ................................ 84
Operating the signal horn .............................................. 94
Seatbelt .......................................................... 95
Driver’scab ........................................................ 98
Checkingthebrakesystemforcorrectfunction .............................. 98
Checkingthesteeringsystemforcorrectfunction ............................ 99
Checking the emergency offfunction .....................................100
Zeroadjustmentoftheloadmeasurement(variant) ...........................100
Checking the vertical lift mast position (variant) for correct function . ...............102
Traction ...........................................................103
Safety regulations when driving .........................................103
Roadways .........................................................105
Setting the drive programme ............................................108
Reducing speed with a raised load (variant) ................................109
Selectingthedrivedirection ............................................109
Actuating the drive directionswitch,multiple-leverversion ......................110
Actuatingthedrivedirectionswitch,mini-leverversion .........................111
Actuating the vertical rocker switch for the "drive direction", joystick 4Plus version . . . . 111
Actuate the drive directionswitch,fingertipversion ...........................112
Actuatingthedrivedirectionswitch,mini-consoleversion ......................112
Startingdrivemode ..................................................112
Starting drive mode, dual-pedal version (variant) .............................115
Operatingtheservicebrake ............................................117
Parkingbrake .................................................... . . 118
Actuating the mechanicalparkingbrake ...................................118
Actuatetheelectricparkingbrake ........................................120
Steering ...........................................................127
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Reducing speed when turning (Curve Speed Control) .........................128
Lifting ............................................................129
Liftingsystemvariants ................................................129
Automaticliftcutout(variant) ...........................................129
Liftmastverticalposition(variant) ........................................130
Typesofliftmast ....................................................134
Malfunctionsduringliftingmode .........................................136
Liftingsystemoperatingdevices .........................................137
Hydraulic blocking function .............................................138
Multi-leverliftingsystem ...............................................139
Controlling the lifting system using a double mini-lever .........................140
Controlling the lifting systemusingatriplemini-lever ..........................141
Controlling the lifting system using a quadruple mini-lever ......................142
Controllingtheliftingsystemusingthejoystick4Plus ..........................143
Controlling the lifting systemwiththefingertipconsole .........................145
Changing the fork arms ...............................................146
Forkextension(variant) ...............................................148
Operation with reversibleforkarms(variant) ................................150
Handling loads ......................................................152
Safety regulations when handing loads ....................................152
Beforetakingupload .................................................15
3
Loadmeasurement(variant) ...........................................154
Picking up loads .....................................................157
Danger area .......................................................158
Transportingpallets ..................................................159
Transporting suspended loads ..........................................159
Loadpickup ...................................................... . 160
Transporting loads ...................................................164
Setting down loads ...................................................165
Driving on ascending and descending slopes ...............................167
Drivingonlifts ......................................................167
Drivingonloadingbridges .............................................169
Workingwithattach
ments .............................................170
Fittingattachments ..................................................170
Releasingthepressurefromthehydraulicsystem ............................172
General instructionsforcontrollingattachments .............................174
Controlling attachments using multi-lever operation ...........................176
Controlling attachments using multi-lever operation and the 5th function ...........177
Controlling attachments using a double mini-lever . ...........................179
Controlling attachments using the double mini-lever and the 5th function ...........181
Controllingattachmentsusingatriplemini-lever .............................183
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Controlling attachments using the three-way mini-lever and the 5th function .........185
Controlling attachments using a quadruple mini-lever .........................187
Controlling attachments usingthefour-waymini-leverandthe5thfunction ..........189
Controllingattachmentsviathejoystick4Plus ...............................191
Controlling attachments using the joystick 4Plus and the 5th function . . . ...........192
Controlling the attachments with fingertip . . ................................193
Controlling attachments with fingertip and the 5th function ......................194
Clamp locking mechanism (variant) ......................................196
Taking up a load using attachments ......................................199
Operating auxiliary equipment ..........................................200
Switchingthelightingonandoff .........................................200
Switching the rotating beacononandoff ...................................201
Switchingthehazardwarningsystemonandoff .............................201
Switchingdirectionindicatorsonandoff ...................................202
Switching the double workingspotlightsonandoff. ...........................204
Operatingthewindscreenwiper/washer ...................................206
FleetManager (variant) . ...............................................206
Accident recorder (variant) .............................................207
Driverrestraintsystems(variants) .......................................207
Cab operation ......................................................208
Opening the cab door . . ...............................................208
Closingthecabdoor ............................................... . . 209
Openingthesidewindows ........................................... . . 209
Closing the side windows ..............................................209
Operatingtheinteriorlighting ...........................................210
Operating the rear window heating .......................................211
Radio(variant) ......................................................211
Heatingsystem(variant) ..............................................212
Push-up roof window (variant) ..........................................215
Clipboard (variant) ...................................................215
Trailer operation ....................................................216
Towedload ....................................................... . 216
Coupling pin in the counterweight ........................................217
Automatic tow coupling ...............................................219
Towingtrailers ......................................................227
Useincoldstores ....................................................22
9
Operating the display and operating unit ...................................232
Indicators .........................................................232
Adjusting the displays ................................................235
Symbolsinthedisplay ................................................235
Settingthedateortime ................................................240
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Resetting the daily kilometres and daily operating hours .......................240
Setting the language .................................................241
Soft key button for operating various equipment variants .......................241
Blue-Q efficiency mode ...............................................243
Functionaldescription ................................................243
Effects on additional consumers .........................................243
SwitchingefficiencymodeBlue-Qonandoff ................................244
ConfiguringBlue-Qefficiencymode ......................................245
Display messages ...................................................247
Displaycontent .....................................................247
Errorcodetable .....................................................247
General messages ...................................................250
Drive-specificmessages ..............................................259
Operating in special operating situations ...................................262
Transport ..........................................................262
Towing .......................................................... . 265
Craneloading ......................................................267
Procedure in emergencies.............................................270
Emergency shutdown ................................................271
Procedureiftrucktipsover .............................................272
Emergency hammer ..................................................273
Emergency lowering .................................................273
Emergency operation of the electric parking brake . ...........................275
Handling the battery ..................................................2
77
Safety regulations when handling the battery ...............................277
Opening/closing the battery cover ........................................280
Disconnecting the battery male connector ..................................283
Maintainingthebattery ................................................284
Checkingthebatterycondition,acidlevelandaciddensity ......................286
Checking the battery chargestatus .......................................287
Chargingthebattery ..................................................287
Equalisingchargetopreventadeepdischargeofthebattery ....................290
Changing to a differentbatterytype .......................................292
General information on replacing the battery ................................292
Replacingthebatteryusingforklifttruckorpallettruck .........................293
Battery transport withcrane ............................................296
Replacing the battery using a change frame (variant) ..........................296
Replacingthebatterywiththehydraulicbatterycarrier .........................301
Charging the batterywiththebatterychargingflap ............................308
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Decommissioning ...................................................313
Parkingthetrucksecurelyandswitchingitoff ...............................313
Wheelchock(variant) ................................................315
Shuttingdownandstoringthetruck ......................................315
Recommissioningafterstorage .........................................317
Cleaning ..........................................................319
Cleaningthetruck ...................................................319
Cleaningtheelectricalsystem ..........................................321
Cleaningloadchains .................................................322
Cleaningthewindows .............................................. . . 323
Afterwashing .......................................................323
6 Maintenance
General maintenance information ........................................326
Personnel qualifications ...............................................326
Informationforcarryingoutmaintenance ..................................326
Maintenance — 1000 hours/annually .....................................329
Maintenance - 3000 hours/every two years . ................................333
Orderingsparepartsandwearingparts ....................................333
Quality and quantity of the required operating materials ........................333
Lubricationplan .....................................................334
Maintenance data table ...............................................336
Safety regulations for maintenance .......................................339
Generalinformation ..................................................339
Workingonthehydraulicequipment ......................................339
Working on the electrical equipment ......................................339
Safetydevices ......................................................340
Setvalues ....................................................... . . 340
Lifting and jacking up .................................................340
Workingatthefrontofthetruck ..........................................341
Providing access to maintenance points ...................................343
Removing/installingthevalvecover ......................................343
Servicing ..........................................................344
Lubricatingthejointsandcontrols ........................................344
Checking the batteryinterlockandbatterycover .............................344
Maintainingtheseatbelt ...............................................346
Checkingthedriver’sseat .............................................347
Maintaining wheelsandtyres ...........................................348
Servicingthesteeringaxle .............................................350
Checkingthebattery .................................................352
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Checkingthefuses ...................................................352
Replacingfuses .....................................................354
Checking the hydraulic oil level ..........................................356
Checkingthehydraulicsystemforleaks ...................................357
Lubricatingtheliftmastandrollertrack ....................................358
Greasing the automatic tow coupling ......................................358
Maintenancefortrucksusedincoldstores .................................361
Maintaining the heater ................................................361
1000-hour maintenance/annual maintenance ...............................363
Othertasks ........................................................363
Checking the cable connections .........................................363
Checking the function of thebatterycoversensor ............................363
Checkingthehydraulicoillevelofthehydraulicbatterycarrier ...................364
Lubricatingtheslideelements ..........................................366
Oilingthecatchrails ..................................................366
Checking the lift cylinders and connections for leaks ..........................368
Checkingforkarms ..................................................369
Checking the reversible forkarms ........................................369
Checking the double pedal . . . ..........................................370
Checking the battery changeover frame ...................................370
7 Technical data
Dimensions ........................................................372
VDI datasheet for RX60-25 and RX60-25/600 ...............................374
VDI datasheet for RX60-25L and RX60-25L/600 .............................378
VDI datasheet for RX60-30 and RX60-35 ..................................382
VDI datasheet for RX60-30L and RX60-30L/600 .............................386
Ergonomic dimensions ................................................390
Battery specifications .................................................391
Fuse assignment ....................................................393
Fuse assignment standard equipment ....................................393
Fuse assignment equipmentvariants .....................................394
X5
6338011803 EN - 10/2016

1
Foreword

1Foreword
Your truck
Your truck
General
The truck described in these operating instruc-
tions corresponds to the applicable standards
and safety regulations.
If the truck is to be operated on public roads, it
must conform to the existing national regula-
tions for the country in which it is being used.
The driving permit must be obtained from the
appropriate office.
Thetruckshavebeenfittedw
ith state-of-the-
art technology. All that remains is to handle
the truck safely and maintain its functionality.
These operating instructions provide the
necessary information to do this. Read and
observe the information provided before
commissioning the truck. This will prevent
accidents and ensure that the warranty
remains valid.
CE-Symbol
CE labelling
The manufacturer uses CE labelling to indi-
cate that the truck complies with the standards
and regulations valid at the time of marketing.
This is confirmed by the issued EC declaration
of conformity. The CE labelling is attached to
the nameplate.
An independent structural change or addition
to the truck can compromise safety, thus
invalidating the EC declaration of conformity.
The EC declaration of conformity must be
carefully stored andmadeavailabletothe
responsible authorities.
25
6338011803 EN - 10/2016

Foreword 1
Your truck
EC declaration of conformity in accordance with Machinery Directive
Declaration
STILL GmbH
Berzeliusstraße 10
D-22113 Hamburg Germany
We declare that the
Industrial truck according to these operating instructions
Model according to these operating instructions
conforms to the latest version of the Machinery Directive 2006/42/EC.
Personnel authorised to compile the technical documents:
See EC compliance declaration
STILL GmbH
.
56338011803 EN - 10/2016 3

1Foreword
Your truck
Accessories
• Key for key switch (2 pieces)
• Key for cab (variant)
• Hexagon socket wrench for emergency
lowering
• Battery replacement frame
45
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Foreword 1
Information about the documentation
Information about the documentation
Documentation scope
• Original operating instructions
• Original operating instructions for attach-
ments (variant)
• Spare parts list
• VDMA rules for the proper use of industrial
trucks
These operating instructions describe all mea-
sures necessary for the safe operation and
proper maintenance of your truck in all pos-
sible variants available at the time of printing.
Special versions to meet customer require-
ments are documented in separate operating
instructions. If you have any questions, please
contact your authorised service centre.
Enter the production number and year of
manufacturer from the nameplate in the space
provided:
Production number
...............................................
Year of manufacture
...................................................
Please quote the production number during all
technical enquiries.
Each truck comes with a set of operating
instructions. These instructions must be
stored carefully and must be available to the
driver and operating company at any time. The
storage location is specified in the "Overviews"
chapter.
If the operating instructions are lost, the
operator must obtain a replacement from the
manufacturer immediately.
The operating instructions are included in the
spare parts list and can be reordered there as
a spare part.
The personnel responsible for operating and
maintaining the equipment must be familiar
with these operating instructions.
The operating company must ensure that all
users have received, read and understood
these operating instructions.
56338011803 EN - 10/2016 5

1Foreword
Information about the documentation
NOTE
Please observe the definition of the following
responsible persons: "operating company"
and "driver".
Thank you for reading and complying with
these operating instructions. If you have any
questions or suggestions for improvements,
or if you have found any errors, please contact
the authorised service centre.
Issue date and topicality of the
operating instructions
The issue date of these operating instructions
can be found on the title page.
STILL is constantly engaged in the further
development of trucks. These operating
instructions are subject to change, and any
claims based on the information and/or
illustrations contained in them cannot be
asserted.
Please contact your authorised service centre
for technical support relating to your truck.
Copyright and trademark rights
These instructions must not be reproduced,
translated or made accessible to third par-
ties—including as excerpts—except with the
express written approval of the manufacturer.
Explanation of information symbols
used
DANGER
Indicates procedures that must be strictly adhered
to in order to prevent the risk of fatalities.
WARNING
Indicates procedures that must be strictly adhered
to in order to prevent the risk of injuries.
65
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Foreword 1
Information about the documentation
CAUTION
Indicates procedures that must be strictly adhered
to in order to prevent material damage and/or
destruction.
NOTE
For technical requirements that require
special attention.
ENVIRONMENT NOTE
To prevent environmental damage.
List of abbreviations
NOTE
This list of abbreviations applies to all types
of operating instructions. Not all of the abbre-
viations that are listed here will necessarily
appear in these operating instructions.
Abbrevi-
ation Meaning Explanation
ABE Display operating unit
Arb-
SchG Arbeitsschutzgesetz German implementation of EU occupa-
tional health and safety directives
Betr-
SichV Betriebssicherheitsverordnung German implementation of the EU work-
ing equipment directive
BG Berufsgenossenschaft German insurance company for the
company and employees
BGG Berufsgenossenschaftlicher Grundsatz German principles and test specifications
for occupational health and safety
BGR Berufsgenossenschaftliche Regel German rules and recommendations for
occupational health and safety
DGUV Berufsgenossenschaftliche Vorschrift German accident prevention regulations
CE Communauté Européenne Confirms conformity with product-specific
European directives (CE mark)
CEE Commission on the Rules for the Approval
of the Electrical Equipment
International commission on the rules for
the approval of electrical equipment
DC Direct Current Direct current
DFÜ Datenfernübertragung Remote data transmission
DIN Deutsches Institut für Normung German standardisation organisation
EG European Community
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1Foreword
Information about the documentation
Abbrevi-
ation Meaning Explanation
EN European standard
FEM Fédération Européene de la Manutention European Federation of Materials Han-
dling and Storage Equipment
Fmax maximum Force Maximum power
GAA Gewerbeaufsichtsamt
German authority for monitoring/issuing
regulations for worker protection, environ-
mental protection, and consumer protec-
tion
GPRS General Packet Radio Service Transfer of data packets in wireless
networks
ID no. ID number
ISO International Organization for Standard-
ization International standardisation organisation
LAN Local Area Network Local area network
KpA Uncertainty of measurement of sound
pressure levels
LED Light Emitting Diode Light emitting diode
LpSound pressure level at the workplace
LpAZ Average continuous sound pressure level
in the driver’s compartment
LSP Load centre of gravity Distance of the centre of gravity of the load
from the front face of the fork backs
MAK Maximum workplace concentration Maximum permissible air concentrations
of a substance at the workplace
Max.Maximum Highest value of an amount
Min.Minimum Lowest value of an amount
PIN Personal Identification Number Personal identification number
PPEPersonal protective equipment
SE Super-Elastic Superelastic tyres (solid rubber tyres)
SIT Snap-In Tyre Tyres for simplified assembly, without
loose rim parts
StVZO Straßenverkehrs-Zulassungs-Ordnung German regulations for approval of
vehicles on public roads
TRGS Technische Regel für Gefahrstoffe Ordinance on hazardous materials appli-
cable in the Federal Republic of Germany
VDE Verband der Elektrotechnik Elektronik
Informationstechnik German technical/scientific association
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